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Integrally Geared Centrifugal Air Compressor Vibration Analysis Case Studies 15-Feb-2008

13 Aberdeen Way Elgin, SC 29045 Tel. (803) 427-0791. Integrally Geared Centrifugal Air Compressor Vibration Analysis Case Studies 15-Feb-2008. By: Timothy S. Irwin, P.E. Senior Engineer tsi @ mbesi.com.

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Integrally Geared Centrifugal Air Compressor Vibration Analysis Case Studies 15-Feb-2008

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  1. 13 Aberdeen Way Elgin, SC 29045 Tel. (803) 427-0791 Integrally GearedCentrifugal Air CompressorVibration Analysis Case Studies15-Feb-2008 By: Timothy S. Irwin, P.E.Senior Engineertsi@mbesi.com Rotating Machinery Diagnostics & Instrumentation Solutions for… “Maintenance That Matters” www.mbesi.com

  2. Integrally Geared Air Compressors Integrally Geared Air Compressor Case Studies Vibration Institute Piedmont Chapter Meeting Augusta, GA 15-Feb-2008

  3. Integrally Geared Air Compressors • How do we monitor these types of machines? • What kind of components are we trying to monitor in these machines? • High speed gearing • High speed shafts / impellers • Low speed shafts • Geared couplings • Disc or shim-pack couplings • Sleeve bearings • Multi-segment tilt pad bearings This does not include the driver which could be a motor or turbine of which either one can add more complexities to the setup of a monitoring route Integrally Geared Air Compressor Case Studies Vibration Institute Piedmont Chapter Meeting Augusta, GA 15-Feb-2008

  4. Integrally Geared Air Compressors • What parameters do we have available for monitoring the overall condition? • Bearing temperatures • Stage and drive gear vibration • Stage inlet and outlet temperatures • Stage inlet and outlet pressures • Intercooler inlet and outlet temperatures • Intercooler inlet and outlet pressures • Motor amperage or kW • There are a lot of parameters that can be used including the above items and: • Performance testing • Oil Analysis • And visual inspections Integrally Geared Air Compressor Case Studies Vibration Institute Piedmont Chapter Meeting Augusta, GA 15-Feb-2008

  5. Integrally Geared Air Compressors • What do we use to monitor the vibration of the machine? • Is there a permanent probe of some kind on each stage? • Is there a permanent monitoring / vibration protection system installed? • Or are our only options temporary accelerometers? • Many permanent monitoring systems will have proximity probes on each stage, • are they? • A single probe on the stage? • Dual probes at 90 degrees? • Any there permanent accelerometers? • Can you ‘plug-in’ to obtain the raw signal in your portable data collector? Integrally Geared Air Compressor Case Studies Vibration Institute Piedmont Chapter Meeting Augusta, GA 15-Feb-2008

  6. Integrally Geared Air Compressors • Vibration Analysis: • Proximity probe use • Magnetically mounted accelerometers • High Frequency accelerometers To use the above probes we need to figure out the expected fault frequencies So that we can set up the appropriate frequency spans and resolutions The following segments of the case studies will be on several Joy (Cameron Compression) MSG 4-stage machines Integrally Geared Air Compressor Case Studies Vibration Institute Piedmont Chapter Meeting Augusta, GA 15-Feb-2008

  7. Case Study #1 – Cameron Compression MSG • What are typical Fault Frequencies: • Shaft Running Speeds • Journal Bearing Issues • Gear Mesh (and other gear fault frequencies) • Vane Pass (diffuser vs. impeller) • Coupling/Alignment • Motor • Shaft Running Speeds • Journal Bearing Issues • Electrical Frequencies Integrally Geared Air Compressor Case Studies Vibration Institute Piedmont Chapter Meeting Augusta, GA 15-Feb-2008

  8. Case Study #1 – Cameron Compression MSG • Example Fault Frequencies: • Shaft Speeds: • Motor, Couplings, & Gear – 1781 rpm • Pinion Speeds – 14,385 & 21,372 rpm • Gears (420 teeth, 52 teeth, 35 teeth): • Gear Mesh – 748,020 (12,467 Hz) • Assembly phase – 187,000 & 21,372 cpm • Hunting Tooth – 1198, 203 cpm • Vane Pass – 362,100 cpm (for bladed diffuser) Integrally Geared Air Compressor Case Studies Vibration Institute Piedmont Chapter Meeting Augusta, GA 15-Feb-2008

  9. Case Study #1 – Cameron Compression MSG Displacement – Velocity – Acceleration What is an acceptable measurementfrequency range: 3600 rpm 20,000 rpm 750,000 cpm Displacement (mils) 1 1 1 Velocity (in/s) 0.19 1.05 39.3 Acceleration (g) 0.18 5.68 7988 3600 rpm 20,000 rpm 750,000 cpm Displacement (mils) 27 0.88 0.0006 Velocity (in/s) 5.1 0.921 0.025 Acceleration (g) 5 5 5 Integrally Geared Air Compressor Case Studies Vibration Institute Piedmont Chapter Meeting Augusta, GA 15-Feb-2008

  10. Case Study #1 – Cameron Compression MSG Note the step changes in the trend plot Integrally Geared Air Compressor Case Studies Vibration Institute Piedmont Chapter Meeting Augusta, GA 15-Feb-2008

  11. Case Study #1 – Cameron Compression MSG Note the variations in amplitude over time Integrally Geared Air Compressor Case Studies Vibration Institute Piedmont Chapter Meeting Augusta, GA 15-Feb-2008

  12. Case Study #1 – Cameron Compression MSG Here is a recent comparison to the other stages on the same machine Integrally Geared Air Compressor Case Studies Vibration Institute Piedmont Chapter Meeting Augusta, GA 15-Feb-2008

  13. Case Study #1 – Cameron Compression MSG Just after the startup Integrally Geared Air Compressor Case Studies Vibration Institute Piedmont Chapter Meeting Augusta, GA 15-Feb-2008

  14. Case Study #1 – Cameron Compression MSG This is only 6 days later Integrally Geared Air Compressor Case Studies Vibration Institute Piedmont Chapter Meeting Augusta, GA 15-Feb-2008

  15. NER - #6 JOY #6 AIRCOMP-P2B PANEL POINT TWO 2ND STAGE BOTTOM 07-Jan-08 Max Amp 15:41:50 .86 Plot Scale 10-Dec-07 0.9 08:59:07 P-P Displacement in Mils 0 20-Nov-07 09:20:50 08-Oct-07 14:47:17 13-Sep-07 11:17:33 Freq: 19.05 0 30 60 90 120 Ordr: 1.004 Frequency in kCPM Sp 1: .862 Case Study #1 – Cameron Compression MSG 1X Amplitudes at different samples: 0.793; 0.851; 0.709; 0.713; 0.862 Integrally Geared Air Compressor Case Studies Vibration Institute Piedmont Chapter Meeting Augusta, GA 15-Feb-2008

  16. Case Study #1 – Cameron Compression MSG Integrally Geared Air Compressor Case Studies Vibration Institute Piedmont Chapter Meeting Augusta, GA 15-Feb-2008

  17. Case Study #2 – Cameron Compression MSG Note the difference in the noise floor of a 10 mV/g vs. 100 mV/g Integrally Geared Air Compressor Case Studies Vibration Institute Piedmont Chapter Meeting Augusta, GA 15-Feb-2008

  18. Case Study #2 – Cameron Compression MSG Integrally Geared Air Compressor Case Studies Vibration Institute Piedmont Chapter Meeting Augusta, GA 15-Feb-2008

  19. Case Study #2 – Cameron Compression MSG Integrally Geared Air Compressor Case Studies Vibration Institute Piedmont Chapter Meeting Augusta, GA 15-Feb-2008

  20. Case Study #2 – Cameron Compression MSG Now we are at 20 kHz Frequency Span Integrally Geared Air Compressor Case Studies Vibration Institute Piedmont Chapter Meeting Augusta, GA 15-Feb-2008

  21. Case Study #2 – Cameron Compression MSG Now we are at 50 kHz Integrally Geared Air Compressor Case Studies Vibration Institute Piedmont Chapter Meeting Augusta, GA 15-Feb-2008

  22. Case Study #2 – Cameron Compression MSG Are the overall amplitudes really higher than expected? Integrally Geared Air Compressor Case Studies Vibration Institute Piedmont Chapter Meeting Augusta, GA 15-Feb-2008

  23. Case Study #2 – Cameron Compression MSG Differing time frames from the high frequency accel Integrally Geared Air Compressor Case Studies Vibration Institute Piedmont Chapter Meeting Augusta, GA 15-Feb-2008

  24. Case Study #3 – Cameron Compression MSG Raw Timebase or Waveform High Frequency Enveloping Integrally Geared Air Compressor Case Studies Vibration Institute Piedmont Chapter Meeting Augusta, GA 15-Feb-2008

  25. Case Study #4 – Ingersoll-Rand Centac II Note the amplitudes Integrally Geared Air Compressor Case Studies Vibration Institute Piedmont Chapter Meeting Augusta, GA 15-Feb-2008

  26. Case Study #4 – Ingersoll-Rand Centac II Integrally Geared Air Compressor Case Studies Vibration Institute Piedmont Chapter Meeting Augusta, GA 15-Feb-2008

  27. Case Study #4 – Ingersoll-Rand Centac II Integrally Geared Air Compressor Case Studies Vibration Institute Piedmont Chapter Meeting Augusta, GA 15-Feb-2008

  28. Thank You – Any Questions? Integrally Geared Air Compressor Case Studies Vibration Institute Piedmont Chapter Meeting Augusta, GA 15-Feb-2008

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